NASA SUPPLY CHAIN 2012 CONFERENCE · 2013-06-03 · NASA SUPPLY CHAIN 2012 CONFERENCE PROJECT...
Transcript of NASA SUPPLY CHAIN 2012 CONFERENCE · 2013-06-03 · NASA SUPPLY CHAIN 2012 CONFERENCE PROJECT...
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NASA SUPPLY CHAIN 2012 CONFERENCE
PROJECT MANAGEMENT AND PRODUCT QUALITY IN LEAN ORGANIZATIONS
Tom Macdonald
Vice President Aerospace Division
Adcole Corporation
669 Forest Street
Marlborough, Massachusetts
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Adcole Corporation
! Established 1957, Privately Held, a Small Business ! World Leader in two “niche” Markets
– Sun Sensors for Space Applications – Gaging Machines for the Automotive Industry: measure camshafts,
crankshafts to sub micron tolerances ! 130 Employees at Marlborough Facility, <40 in Aerospace Division
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Adcole Aerospace Division Sun Sensor Applications
Fine Sun Sensors
• Spacecraft Attitude Control
• Instrument Pointing
• Solar Array Pointing
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Sun Sensor Operation
Simplicity of optical design provides high reliability and is tolerant of extreme radiation and thermal environments
! The Sun Sensor Head consists of patterned optics which modulate the incident sunlight, and multisegment solar cells which convert the incident illumination into a short circuit current.
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Electronics Processing
! The Electronics unit receives the Sensor Head signals and outputs digital sun angle data
! Typical Electronics unit
contains the following: – Power supply with EMI
filtering – Multiplexer for multiple
Sun Sensor Heads – Fine and Coarse angle
processors – Standard or custom data
interface
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analog sun sensor - wide FOV low accuracy
digital sun sensor - wide FOV moderate accuracy
spinning sun sensor for spin- stabilized spacecraft
fine sun sensor – wide FOV high accuracy
2 axis fine sun sensor – wide FOV high accuracy
fine pointing sun sensor – narrow FOV, very high accuracy
Sun Sensor Product Family
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Sun Sensor Heritage: NASA/JPL
• MARS MISSIONS:
-MARS SURVEYOR
-MARS PATHFINDER
-MRO
-MARS EXPLORATION ROVERS
-MARS SCIENCE LAB
-MAVEN
• OTHER INTERPLANETARY MISSIONS:
- CASSINI TO SATURN
- MESSENGER TO MERCURY
- NEW HORIZONS TO PLUTO
- JUNO TO JUPITER
• NASA SCIENTIFIC SATELLITES: -NUMEROUS INCLUDING:
IUE, EOS, GRO, EUVE, SOLAR MAX, TOPEX, MAGSAT, ERBS, SMEX, COBE, SOHO, SORCE, XTE, CHANDRA, TRMM, ST-5, LRO/LCROSS, THEMIS, SDO, STEREO, RBSP, GRAIL, GPM
• WEATHER/DATA SATELLITES:
-TIROS/DMSP
-TDRSS
-GOES
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Business Segments
! US Commercial Communication Satellites
– Always schedule and price critical, require maximum use of standard documentation, little or no non recurring effort
! NASA/JPL
– Current Programs include MMS, GOES, TDRSS, SMAP, SOLAR PROBE PLUS
– Typically have unique operational and/or environmental requirements driving significant design modifications
! US Military – GPS, AEHF, SBIRS, etc – Typically have significant analysis and documentation requirements plus
unique survivability requirements
! Foreign: Commercial, JAXA, etc. – Communication restrictions, ITAR compliance, US vs Non US Derived
programmatic requirements
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Lean Management: Adcole Philosophy
Adcole’s Goal on Every Program is to be the supplier that our customer does not have to worry about.
! Keep it Simple ! Personal Responsibility
– Typical of many small companies, successful management is more dependent on people than on management procedures or templates
! Responsiveness: – Positive long term relationships with customers are built on a
day by day basis.
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Lean Management: Adcole Philosophy
! Most programs ultimately have the same key areas critical to successful implementation:
– Design/Analysis – EEE Parts, and Materials and Processes: Compliance to Program
Requirements – Manufacturing: Workmanship Standards, Program Unique
Requirements, etc – Testing: Compliance/Verification of imposed requirements
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Program Implementation: Design/Analysis
! Philosophy: No Bid or push back on Plans such as Reliability Plan, Producibility Plan, Management Plans, etc. Emphasize analyses.
! Key analyses done on all programs:
– Worst Case Analysis – Radiation/Survivability Analysis – Part Stress Analysis – Reliability Analysis – EMC Assessment – FMECA – Mission Unique Analyses: Planetary Albedo, Thermal Analyses/Models,
etc.
! Teamwork: Take advantage of experienced workforce to optimize design for manufacture and testability.
– Inputs from inspectors, assembly and test techs on all new designs
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Program Implementation EEE Parts
! Design Philosophy: Maximize use of rad hard SMD Level V or JANS parts, avoid hybrids whenever possible
! Identify non standard SCD parts in proposal phase and offer most attractive pricing based on use of existing part specifications-justify via flight heritage
! EEE Part Program Plan: For each program, Adcole creates one document in a standard format:
– Defines As-Procured P/N, Procurement Spec, MFR, post receipt
processing such as DPA, Rad Testing, XRF Testing, unique parameter screening, etc
– Require Customer Approval – Incoming Inspection will only release parts to stock that meet all
requirements of this document.
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Program Implementation: Quality Assurance and Manufacturing
! Assigned QA Engineer responsible for all phases of program from RFP/Proposal to hardware delivery
! Use Adcole AS9100 QA Manual with compliance matrix as QA Program Plan
! Each deliverable hardware item (Sensor Head or Electronics unit) has a unique “Manufacturing, Inspection and Test Flow Plan”
– Includes all program unique requirements: MIPs, Photos, special inspections, XRF testing, etc.
– Reviewed in detail “face to face” with customer at PDR/CDR/MRR.
– All routing tags and build paperwork is generated from the approved Flow Plan.
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Management Controls: Schedules, Risk Management
! Keep it simple: Smaller but understandable schedules are more effective than overly complicated presentations that are difficult to follow or understand
! Risk Management is inherent in good program management and
status communications with customer. At Adcole, it is not a separate entity or function.
! There is no substitute for open communication with the customer.
– Many programs are scheduled serially through our assembly and test areas. A delay on Program A can directly affect Program B. Best way to deal with this is to have a relationship where customer can be open about “real need”, and Adcole can be open about “big picture” of all programs competing for same internal resources.
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Cost Driver for Small Companies
! Requirements for Compliance Verification:
– Documenting Compliance to the Sun Sensor Product Specification and
all direct requirements is standard and no problem.
– With “DOORS” and similar databases, 100% of applicable spacecraft level requirements can now be linked to subcontractor requirements
– Providing “evidence of verification” for every requirement regardless of
whether it is significant or not is an expensive and time consuming effort.
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Summary: Lean Management in Small Companies
! Small Companies: Culture and people are critical. Stability of the work force is a good indicator of the health of the organization.
! Typically have very good depth of knowledge, not as good breadth
of knowledge compared to larger organizations
! Small organizations should be more responsive and flexible than large organizations
! Lean management is a way of life due to lack of large support staffs